Elastic abrasive manufacturing method, elastic abrasive manufacturing device, blasting method, and blasting device

ABSTRACT

A re-circulatory blasting device obtained is capable of performing stable treatment for a prolonged period of time even in cases in which an elastic abrasive employed has abrasive grains adhered to the surface of elastic cores. An elastic abrasive regeneration device provided to the blasting device regenerates elastic abrasive employed for re-circulation. The elastic abrasive regeneration device includes a mixer and a combining unit. Recovered abrasive fed in from an abrasive recovery section is mixed in the mixer with abrasive grains fed in from an abrasive grain feeder, and the abrasive grains are adhered to the surface of the cores of the recovered abrasive. In the combining unit, the abrasive grains are pressed against and combined to the surface of the cores by passing an aggregated state of the recovered abrasive mixed by the mixer along a constricted flow path having a flow path cross-sectional area that gradually narrows.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a method for manufacturing an elasticabrasive, to an elastic abrasive manufacturing device, to a blastingmethod, and to a blasting device. In particular the present inventionrelates to a method for manufacturing an elastic abrasive having astructure in which abrasive grains have been adhered to the surface ofelastic cores, to an elastic abrasive manufacturing device to executethe manufacturing method, and to a re-circulatory blasting method orblasting device of a configuration that includes the elastic abrasivemanufacturing method or manufacturing device to regenerate elasticabrasive employed in re-circulation.

Note that “manufacturing” of the elastic abrasive in the presentinvention includes, in addition to adhering abrasive grains to thesurface of unused cores, “regeneration” in which cores of elasticabrasive in a state in which abrasive grains have become detached fromthe surface of the cores due to use (including a state in which someabrasive grains still remain on the surface), then have abrasive grainsre-adhered to the core surface.

2. Description of the Related Art

There are proposals for various types of elastic abrasives havingabrasive grains supported on cores, such as elastic abrasives in whichabrasive grains are kneaded into elastic cores or elastic abrasives inwhich abrasive grains are adhered to the surface of elastic cores (seeJapanese Patent No. 2957492, Japanese Patent KOKAI (LOPI) No.2001-207160, and microfilm of Japanese Utility Model Application No.S53-178398 (Japanese Utility Model Application Publication NoS55-98565)). By performing blasting employing such elastic abrasives,the shock when impacting a workpiece is absorbed by the elasticity ofthe cores, and as a result this enables treatment such as polishing aworkpiece and removing an oxidized film or burrs from a workpiece to beperformed while suppressing a matt (satin) finish from being formed onthe surface of a workpiece, as would occur when ordinary blasting isperformed.

In particular, for elastic abrasives employing cores with suppressedimpact resilience to prevent recoil at impact, causing the ejectedelastic abrasive to slide over the surface of a workpiece has enabledmirror finish polishing to be performed, which was not possible withconventional blasting, and is making a significant contribution toexpanding the range of fields for treatment by blasting (see JapanesePatent KOKAI (LOPI) No. 2006-159402).

Structures of such elastic abrasives include elastic abrasives in whichabrasive grains are supported by cores by kneading the abrasive grainsinto cores configured by an elastic material such as rubber (seemicrofilm of Japanese Utility Model Application No. S53-178398 (JapaneseUtility Model Application Publication No S55-98565)), as well asstructures in which abrasive grains are adhered to the surface of cores,such as cores configured from plant fibers including an oil or sugarcomponent with adhesive properties (Japanese Patent No. 2957492), orcores made from gelatin that exhibits both adhesive properties andelasticity due to containing a water component (Japanese Patent KOKAI(LOPI) No. 2001-207160).

From out of such elastic abrasives, in cases in which blasting isperformed using an elastic abrasive having a structure in which abrasivegrains have been adhered to the surface of cores, the abrasive grainsadhered to the surface of the cores of the elastic abrasive are fallenoff by shock and friction during impact, resulting in the quantity ofabrasive grains adhered to the core surface reducing as the number oftimes of impact against the workpiece increases.

This means that when blasting is performed using an elastic abrasive ina re-circulatory type blasting device, as illustrated in FIG. 10, thecutting performance of the elastic abrasive gradually decreases with thepassage of time, resulting in a large difference arising in surfacestate, such as glossiness or mirror finish, between a state of treatmentof a workpiece when treatment was performed employing the elasticabrasive in a new state, and a state of treatment of a workpiece whentreatment was performed employing the elastic abrasive that has alreadybeen used repeatedly.

Even in cases in which the elastic abrasive is replaced with new elasticabrasive at prescribed intervals of time in order to prevent suchchanges in treatment state from occurring, although there is a temporaryincrease in cutting rate directly after replacement, from then onwardsthe cutting rate decreases with the passage of time. The cutting rateaccordingly becomes unstable and changes as illustrated in FIG. 10,meaning that, as before, performing treatment to a workpiece at aconstant quality remains unattainable.

In order to address this issue, in cases in which blasting is performedusing elastic abrasive with a structure in which abrasive grains areadhered to the surface of cores, there is a need to either perform batchprocessing while replacing the elastic abrasive after each batch use, ora need to replace elastic abrasive being used by re-circulation with newelastic abrasive several times at short intervals. This results in ahigher cost due to the increase in the amount of elastic abrasiveconsumed, and suffers from the problem of there being a significantdecrease in productivity due to interrupting blasting operation eachtime the elastic abrasive is replaced.

In consideration of such problems, the inventors of the presentinvention have submitted a patent application for a blasting deviceincorporating an elastic abrasive regeneration device, and alreadyreceived a patent therefor (see Japanese Patent No. 6254409).

The elastic abrasive regeneration device provided in this blastingdevice includes a mixer and a combining unit. The combining unit mixessome recovered abrasive that has been recovered in an abrasive recoverysection of the blasting device together with abrasive grains fed in froman abrasive grain feeder and feeds these into a gas flow to generate asolid-gas two-phase flow in which the abrasive grains and cores aremixed together. The combining unit includes a convoluted space, forexample a spiral shaped pipeline, through which the solid-gas two-phaseflow generated in the mixer is passed.

At least a portion of the elastic abrasive employed for re-circulationcan be regenerated by adhering abrasive grains to the surface of coresof recovered abrasive by mixing in the mixer, and by then pressing theabrasive grains against and combining the abrasive grains to the surfaceof cores using propulsive force of the solid-gas two-phase flow orcentrifugal force when being passed through the combining unit includingthe convoluted space (see Japanese Patent No. 6254409).

In blasting performed with elastic abrasive using re-circulation, inorder to perform blasting such as polishing at a constant quality for aprolonged period of time, the abrasive grains need to be combined to thesurface of the cores at high density and with high strength so as tomake the abrasive grains adhered to the surface of the cores difficultto fall off and such that the treatment properties do not change greatlyeven if a small amount of the abrasive grains is actually fallen off.The abrasive grains accordingly need to be sufficiently pressed againstthe surface of cores when combining the abrasive grains to the coresurface in order to combine the abrasive grains with high density andhigh strength.

Thus in the elastic abrasive regeneration device of Japanese Patent No.6254409, after the abrasive grains have been adhered to the surface ofthe cores using the adhesive properties of the cores by mixing in themixer 11, the solid-gas two-phase flow including such cores is fed intothe convoluted space of the combining unit, which is a spiral shapedspace in this example, and the abrasive grains that have been adhered tothe surface of the cores by propulsive force of the solid-gas two-phaseflow or centrifugal force when passing through the convoluted space, arefurther pressed against the surface of the cores and strongly combinedthereto.

However, the convoluted space referred to above needs to be providedover a comparatively long distance in order to strongly combine theabrasive grains to the surface of the cores using the above method.

Moreover, the most appropriate pressing force to combine the abrasivegrains to the cores varies according to the physical properties of thecores employed (for example, the hardness, extensibility, coefficient ofrestitution, adhesive strength, grain size), the physical properties ofthe abrasive grains being adhered (for example, the grain size andshape, and material), and the environmental conditions (temperature,humidity, and the like). Thus adjusting the pressing force of theabrasive grains against the surface of the cores is difficult in themethod described in Japanese Patent No. 6254409.

There is accordingly a desire to develop an elastic abrasivemanufacturing method and manufacturing device that, similarly to themethod described in Japanese Patent No. 6254409, enables abrasive grainsto be strongly combined to the surface of cores, but employs a simplerconfiguration while also enabling adjustment of the pressing force ofthe abrasive grains to the surface of the cores.

The present invention addresses such a desire, and an object of thepresent invention is to provide an elastic abrasive manufacturing methodand manufacturing device that enables abrasive grains to be pressedagainst cores and strongly combined thereto, similarly to in thecombining process and combining unit adopted in Japanese Patent No.6254409, but employs a comparatively simpler configuration, andpreferably includes a combining process and combining unit capable ofcomparatively easily adjusting the pressing force of the abrasive grainsagainst the surface of the cores. An object is also to provide are-circulatory blasting method and blasting device that, byincorporating the elastic abrasive manufacturing method and device,enable blasting to be performed continuously for a prolonged period oftime while maintaining a constant treatment state.

SUMMARY OF THE INVENTION

The following description of means for solving the problem is appendedwith reference signs employed in embodiments for implementing theinvention. These reference signs are employed to clarify correspondencebetween the recitation of the scope of patent claims and the descriptionof embodiments for implementing the invention, and obviously do notlimit the interpretation of the technological scope of the presentinvention.

In order to achieve the object, the present invention relates to themethod and device for manufacturing an elastic abrasive. In the devicefor manufacturing an elastic abrasive 70 having a structure in whichabrasive grains 72 have been combined to a surface of cores 71 that areformed from an elastic material and at least the surface has adhesiveproperties, the elastic abrasive manufacturing device comprises:

a mixer 11 configured to mix the cores 71 and the abrasive grains 72together and to adhere the abrasive grains 72 to the surface of thecores 71; and

a combining unit 12 for executing a combining step in which the abrasivegrains 72 are pressed against and combined to the surface of the cores71 by passing the cores 71 that have completed the mixing processthrough a constricted flow path 121, 121′ having a gradually narrowingflow path cross-sectional area with the cores 71 in an aggregated stateso as to compress aggregate bodies of the cores 71.

The combining process may be executed by forming the constricted flowpaths 121, 121′ between two pressing faces 124, 124 made of two surfacesof walls arranged such that a spacing therebetween gradually narrows onprogression from a wide separation section 125 to a narrow separationsection 126, and passing the cores 71 that have completed the mixingprocess along the constricted flow paths 121, 121′ from the wideseparation section 125 toward the narrow separation section 126 (FIGS. 4and 6).

At least one of the pressing faces 124, 124 may be formed by an outerperipheral face of a cylindrical roller 123 (an outer peripheral face ofportions with oblique lines in FIG. 6), and the combining process isexecuted by rotating the roller 123 so that the pressing face 124 formedby the outer peripheral face of the roller 123 moves along theconstricted flow path 121 from the wide separation section 125 towardthe narrow separation section 126 (See FIG. 6).

Moreover, a plurality of the constricted flow paths 121, 121′ may bearranged in series, and after passing the cores 71 that have completedthe mixing process by the mixer 11 through one constricted flow path 121provided upstream, the cores 71 may also be passed through anotherconstricted flow path 121′ provided downstream of the one constrictedflow path 121, so that pressing of the abrasive grains 72 against thesurface of the cores 71 in the combining process is performed aplurality of times corresponding to the number of the constricted flowpaths 121, 121′ formed (FIG. 6C).

In such case, a flow path cross-sectional area d2 of a narrow separationsection 126 of the other constricted flow path 121′ may be narrower thana flow path cross-sectional area d1 of a narrow separation section 126of the one constricted flow path 121, and a pressing force of theabrasive grains 72 against the surface of the cores 71 in the combiningprocess may be progressively raised in stages (See FIG. 6C).

In a blasting method of the present invention and a blasting device 1 toexecute the method comprises:

a blasting chamber 8 where ejection of an abrasive is performed;

an abrasive recovery section 20 in communication with a bottom sectionof the blasting chamber 8; and

an abrasive ejection means 30 for ejecting abrasive from in the abrasiverecovery section 20 into the blasting chamber 8, with an abrasivere-circulation system being formed to re-circulate the abrasive from theblasting chamber 8, through the abrasive recovery section 20, to theabrasive ejection means 30, and

an elastic abrasive 70 employed as the abrasive having a structure inwhich abrasive grains 72 have been adhered to a surface of cores 71 thatare formed from an elastic material and have adhesive properties atleast at the core surface; and

the blasting device 1 including an elastic abrasive regeneration device10 in which at least some of recovered abrasive 70′ recovered in theabrasive recovery section 20 is regenerated and returned into theabrasive re-circulation system, the regeneration device 10 including

-   -   a mixer 11 configured to mix the recovered abrasive 70′ and the        abrasive grains 72 together and to adhere the abrasive grains 72        to the surface of the cores 71 of the recovered abrasive 70′;        and    -   a combining unit 12 for executing a combining process in which        the abrasive grains 72 are pressed against and combined to the        surface of the cores 71 of the recovered abrasive 70′ by passing        the cores 71 that have completed the mixing process through a        constricted flow path 121 having a gradually narrowing flow path        cross-sectional area with the cores 71 in an aggregated state so        as to compress aggregate bodies of the cores 71.

In the blasting device 1, the combining process may be executed byforming the constricted flow path 121 between two pressing faces 124,124 which are made of the two surfaces of walls arranged such that aspacing therebetween gradually narrows on progression from a wideseparation section 125 to a narrow separation section 126, and passingthe recovered abrasive 70′ that has completed the mixing process by themixer 11 along the constricted flow path 121 from the wide separationsection 125 toward the narrow separation section 126 (See FIGS. 4 to 6).

At least one of the pressing faces 124, 124 may be formed by an outerperipheral face of a cylindrical roller 123 (an outer peripheral face ofportions with oblique lines in FIG. 6), and in such case, the combiningprocess is executed by rotating the roller 123 so that the pressing face124 formed by the outer peripheral face of the roller 123 moves alongthe constricted flow path 121 from the wide separation section 125toward the narrow separation section 126 (See FIG. 6).

Furthermore, a plurality of the constricted flow paths 121, 121′ may bearranged in series, and after the recovered abrasive 70′ that hascompleted the mixing process has been passed along one constricted flowpath 121 provided upstream, the recovered abrasive 70′ may be alsopassed along another constricted flow path 121′ provided downstream ofthe one constricted flow path 121, so that pressing of the abrasivegrains 72 against the surface of the cores 71 in the combining processmay be performed a plurality of times corresponding to the number of theconstricted flow paths 121, 121′ formed (See FIG. 6C).

In such case, it is preferable that a flow path cross-sectional area d2of a narrow separation section 126 of the other constricted flow path121′ is narrower than a flow path cross-sectional area d1 of a narrowseparation section 126 of the one constricted flow path 121, and apressing force of the abrasive grains 72 against the surface of thecores 71 in the combining process is progressively raised in stages (SeeFIG. 6C).

Due to adopting the configuration of the present invention as describedabove, the elastic abrasive manufacturing method and the elasticabrasive manufacturing device of the present invention use the mixer 11to mix the cores 71 (or the recovered abrasive 70′) and the abrasivegrains 72 together, and to adhere the abrasive grains to the surface ofthe cores 71 (the recovered abrasive 70′), and then pass the cores 71(recovered abrasive 70′) that have been mixed by the mixer along theconstricted flow paths 121, 121′ having a gradually narrowing flow pathcross-sectional area while in an aggregated state of the cores 71(recovered abrasive 70′). This enables the abrasive grains 72 to bepressed with a comparatively strong pressing force against the surfaceof the cores 71 by aggregate bodies of the cores 71 (the recoveredabrasive 70′) being compressed as the flow path cross-sectional areadecreases. As a result the abrasive grains 72 that have been adhered bymixing with the mixer 11 can be caused to combine to the surface of thecores 71 at high density and high strength.

Moreover, the pressing force of the abrasive grains 72 against thesurface of the cores 71 can be easily adjusted by changing thecompression ratio on the aggregate bodies of the cores 71 (the recoveredabrasive 70′), such as by changing the flow path cross-sectional area dof the narrow separation section 126. The pressing force of the abrasivegrains 72 against the surface of the cores 71 is according easilychanged to the most appropriate according to the physical properties ofthe cores 71 and the abrasive grains 72, environmental conditions, andthe like.

In a configuration in which the constricted flow path 121, 121′ isprovided between the pressing faces 124, 124 formed by two surfaces ofwalls, the pressing force of the abrasive grains 72 against the surfaceof the cores 71 can be more easily changed according to the physicalproperties of the cores 71 and the abrasive grains 72, the environmentalconditions, or the like by changing an inclination angle of thesepressing faces 124, 124, or by adjusting the separation between thepressing faces 124, 124.

In a configuration in which at least one of the pressing faces 124, 124is formed by an outer peripheral face of a cylindrical roller 123, notonly can the pressing force be easily changed by changing the flow pathcross-sectional area d of the narrow separation section 126 by adjustinga separation between the rollers 123, 123, but the time to pass alongthe constricted flow path 121, and hence the application time ofpressing force, can be adjusted by adjusting the rotation speed of theroller 123, and accordingly finer adjustments can be made to thepressing conditions of the abrasive grains 72 against the surface of thecores 71.

Moreover, in such a configuration in which at least one of the pressingfaces 124, 124 is formed by an outer peripheral face of a cylindricalroller 123, the cores 71 (the recovered abrasive 70′) can be forciblymoved by rotation of the roller 123 and pushed out from the constrictedflow path 121, 121′. This means that even in cases in which the flowpath cross-sectional area d, d1, d2 of the narrow separation section 126is small and compression is performed at a high compression ratio,clogging of the cores 71 (the recovered abrasive 70′) inside theconstricted flow path 121 can be prevented from arising. As a result,this enables the abrasive grains 72 to be pressed against the surface ofthe cores 71 with a higher pressing force, enabling the range ofselectable pressing forces to be expanded.

Furthermore, the abrasive grains 72 can be pressed against the surfaceof the cores 71 plural times in a configuration in which pluralconstricted flow paths 121, 121′ are arranged in series, and after thecores 71 (the recovered abrasive 70′) that have completed the mixingprocess are passed through one constricted flow path 121 providedupstream, they are then also passed through another constricted flowpath 121′ provided downstream of the one constricted flow path 121. Thisenables the abrasive grains 72 to be combined at an even higher densityand higher strength.

In particular, in a configuration in which a flow path cross-sectionalarea d2 of a narrow separation section 126 of the downstream constrictedflow path 121′ is narrower than a flow path cross-sectional area d1 ofthe narrow separation section 126 of the upstream constricted flow path121, the pressing force of the abrasive grains 72 against the surface ofthe cores 71 can be progressively raised in stages, enabling thecombination of the abrasive grains 72 to the surface of the cores 71 tobe performed more uniformly and with a higher combining strength.

The elastic abrasive manufacturing device of the present inventionconfigured as described above, enables provision of the blasting device1 capable of performing blasting continuously for a prolonged period oftime while maintaining a constant treatment precision without replacingthe elastic abrasive 70. This is achieved in the re-circulatory blastingdevice 1 incorporating the elastic abrasive regeneration device 10 bysubjecting at least some of the used recovered abrasive 70′ toregeneration, and by returning the abrasive into the re-circulationsystem after being regenerated by adhering and combining abrasive grainsto the surface of the cores 71 of the recovered abrasive 70′.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects and advantages of the invention will become understood fromthe following detailed description of preferred embodiments thereof inconnection with the accompanying drawings in which like numeralsdesignate like elements, and in which:

FIG. 1A is a front view of a blasting device of the present invention,and FIG. 1B is a side view thereof.

FIG. 2 is an explanatory diagram of an elastic abrasive regeneration(manufacturing) device.

FIG. 3 is a schematic cross-section of a mixer.

FIG. 4A and FIG. 4B are each explanatory diagrams of a combining unithaving a structure in which a constricted flow path is formed betweentwo flat plates, with FIG. 4A illustrating a structure in which bothflat plates are inclined, and FIG. 4B illustrating a structure in whichone of the flat plates is inclined.

FIG. 5 is an explanatory diagram to explain a compressed state ofrecovered abrasive in the combining unit of FIG. 4A.

FIGS. 6A to 6C are each explanatory diagrams illustrating an example ofa configuration of a roller-equipped combining unit, FIG. 6A is of anexample in which a constricted flow path is formed between a flat plateand an outer peripheral face of a roller, FIG. 6B is of an example inwhich a constricted flow path is formed between outer peripheral facesof a pair of rollers, and FIG. 6C is of an example in which constrictedflow paths are formed between outer peripheral faces of two respectivepairs of rollers disposed above and below each other.

FIG. 7 is a schematic diagram of an abrasive grain feeder.

FIG. 8A and FIG. 8B are schematic diagrams of an abrasive grain meteringmeans, FIG. 8A is a cross-section viewed from the front, and FIG. 8B isa cross-section taken along line B-B of FIG. 8A.

FIG. 9 is a graph illustrating changes in cutting rate with respect toejection time in a blasting device (Example) of the present invention.

FIG. 10 is an explanatory diagram illustrating a relationship betweenejection time and cutting rate for conventional blasting employing anelastic abrasive.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Description follows regarding an exemplary embodiment of the presentinvention, with reference to the appended drawings.

Note that in the exemplary embodiment described below, although adescription will be given of an elastic abrasive manufacturing device ofthe present invention for a configuration incorporated as an elasticabrasive regeneration device in a re-circulatory type blasting device,the elastic abrasive manufacturing device of the present invention maybe employed in isolation to manufacture elastic abrasive without beingincorporated into a blasting device.

Elastic Abrasive to be Manufactured (Regenerated)

In the present invention, an elastic abrasive 70 to be manufactured orregenerated has a structure including elastic cores 71 having adhesiveproperties at least at the surface thereof, and abrasive grains 72adhered to the surface of the cores 71. Various materials, dimensions,shapes, and the like may be employed for the elastic abrasive 70 as longas the above structure is achieved. The elastic abrasive 70 may be astructure in which abrasive grains 72 have been adhered to the surfaceof the cores 71 configured from a material with self-adhesiveproperties, such as a gelatin or elastomer, or the elastic abrasive 70may be a structure in which the abrasive grains 72 have been adhered tothe surface of the cores 71 whose surface has been imparted withadhesive properties by coating the surface of a resin such aspolyurethane with a material having self-adhesive properties.

Moreover, various types of abrasive grain may be used as the abrasivegrains 72 employed, and examples employable therefor include diamond,cBN, silicon carbide, alumina, zircon, high speed steels, carbon steelalloys, glass, resins, copper and alloys of copper, aluminum and alloysof aluminum, and the like. Such abrasive grains may be employed singly,or in a combination of plural types thereof. With regard to the particlediameter of the abrasive grains, various particle diameters areselectable according to the application in which the elastic abrasiveobtained therefrom is to be employed, and an example of a selectablerange is a median diameter D50 of from 0.05 μm to 1 mm With regard tothe shape of the abrasive grains, various shapes are selectable, such asirregular, angular, spherical, and columnar shaped abrasive grains.

Blasting Device Overall Structure

FIG. 1A and FIG. 1B illustrate an example of a configuration of ablasting device of the present invention equipped with an elasticabrasive regeneration device 10, described later.

A blasting device 1 illustrated in FIG. 1 is a re-circulatory typeblasting device equipped with a blasting chamber 8 in which abrasiveejection is performed formed inside a cabinet 7, an abrasive recoverysection 20 in communication with a bottom section of the blastingchamber 8 and serving as a recovery hopper for recovering the abrasive,and an abrasive ejection means 30 for ejecting abrasive from inside theabrasive recovery section 20 into the blasting chamber 8. An abrasivere-circulation system is formed from the blasting chamber 8, through theabrasive recovery section 20 and an abrasive feed pipe 41, to theabrasive ejection means 30, in a configuration such that the abrasiveejected by the abrasive ejection means 30 is re-circulated through thesystem, so as to enable the abrasive to be re-ejected by the abrasiveejection means 30.

A blast gun is provided in the illustrated exemplary embodiment as theabrasive ejection means 30 to eject the abrasive in the blasting chamber8, with the blast gun ejecting abrasive carried by a compressed gas froma non-illustrated compressed gas supply. However, there is no limitationto such pneumatic abrasive ejection, and various known types of abrasiveejection means may be employed as the abrasive ejection means 30 that donot use acceleration by compressed gas to enable dry abrasive to beejected or projected (these are collectively referred to as “ejected” inthe present invention), such as an impact type that causes abrasivegrains to impact and be struck out by a rotating impeller, a centrifugaltype in which abrasive is ejected by centrifugal force, or the like.

A bottom section of the blasting chamber 8 where abrasive ejection isperformed using the abrasive ejection means 30 is configured in a hoppershape formed by a funnel shape, in a configuration such that theabrasive ejected in the blasting chamber 8 falls into the abrasiverecovery section 20 formed by this hopper shape.

A baffle (not illustrated in the drawings) for classifying into elasticabrasive and dust is provided inside the blasting chamber 8, and theelastic abrasive classified by the baffle is recovered in the abrasiverecovery section 20, and the dust floating around inside the blastingchamber 8 is fed by an extractor fan (blower) 25 into a dust collector26 provided on the back face of the cabinet 7 where it is collected.

The abrasive feed pipe 41 is communicated with a bottom section of theabrasive recovery section 20 where the elastic abrasive is recovered.The abrasive feed pipe 41 is also communicated with the abrasiveejection means 30, served by the suction type blast gun in theillustrated example.

Note that although an example has been described of a configuration inwhich classification into elastic abrasive and dust is performed in thepresent exemplary embodiment by the baffle referred to above, instead ofsuch a configuration, the abrasive recovery section 20 may, for example,be configured by a cyclone type abrasive tank or the like capable ofclassifying elastic abrasive and the dust.

Compressed air is fed into the blast gun 30 from the non-illustratedcompressed air supply, and abrasive inside the abrasive recovery section20 is sucked through the abrasive feed pipe 41 by a negative pressuregenerated inside the blast gun 30 by the compressed air being fed intothe blast gun 30 from the compressed air supply, so as to enable theabrasive to be ejected together with the compressed air into theblasting chamber 8.

In this manner, in the illustrated re-circulatory type of blastingdevice 1, the abrasive ejected by the abrasive ejection means 30 is fedback into the abrasive ejection means 30 through the blasting chamber 8and the abrasive recovery section 20, and then re-ejected. Forming suchan abrasive re-circulation system achieves a configuration in whichblasting can be performed continuously for a prolonged period of timeusing re-circulation of abrasive.

Elastic Abrasive Regeneration Device

The re-circulatory type blasting device 1 configured as described aboveenables blasting to be performed continuously for a prolonged period oftime by re-circulating and re-using abrasive. However, when the elasticabrasive 70 having a structure in which abrasive grains have beenadhered to the surface of the cores 71 is employed as the abrasive, theabrasive grains 72 adhered to the surface of the cores 71 are fallen offby impact with a workpiece, resulting in a gradual decrease in thecutting performance as the elastic abrasive 70 is repeatedlyre-circulated and re-used. The state of treatment to the workpieceaccordingly changes (see FIG. 10) even when other treatment conditions,such as the ejection pressure and ejection velocity, are held constant.

Thus in the blasting device 1 of the present invention, providing theelastic abrasive regeneration device 10 to regenerate at least some ofthe elastic abrasive for re-circulation inside the abrasivere-circulation system, enables continuous blasting for a prolongedperiod of time without causing changes to the treatment state with thepassage of time.

FIG. 1B and FIG. 2 illustrate the elastic abrasive regeneration device10. The elastic abrasive regeneration device 10 at least includes: amixer 11 to mix recovered abrasive 70′ and abrasive grains together, andto adhere abrasive grains to the surface of the cores 71 of therecovered abrasive 70′ where the surface has been exposed by abrasivegrains being fallen off; and a combining unit 12 that presses abrasivegrains newly adhered to the surface of the cores 71, by mixing using themixer 11, against the surface of the cores 71 and combines the newlyadhered abrasive grains thereto. In the illustrated exemplaryembodiment, the mixer 11 and the combining unit 12 are provided on aflow path separate to the abrasive re-circulation system.

Moreover, the illustrated exemplary embodiment includes an abrasivegrain feeder 13 for feeding abrasive grains into the mixer 11 andprovided with an abrasive grain metering means 131 (see FIG. 1B) capableof varying the quantity of abrasive grains fed into the mixer 11,includes a detection means 14 to measure the adhered amount of abrasivegrains to the surface of the cores 71 of the regenerated elasticabrasive 70 regenerated by combining in the combining unit 12, andincludes a control means 15 that uses received feedback measurementresults from the detection means 14 to control the abrasive grainmetering means 131 to change the quantity of abrasive grains being fedso that the measured adhered amount of abrasive grains approaches apre-set target adhered amount.

Mixer

The mixer 11 mixes the recovered abrasive 70′ to be regenerated togetherwith abrasive grains to be adhered to the surface of the cores 71 of therecovered abrasive 70′, and adheres abrasive grains 72 to the surface ofthe cores 71 of the recovered abrasive 70′ exposed by the abrasivegrains 72 being fallen off.

In the present exemplary embodiment, a solid-gas two-phase flow isgenerated by merging the recovered abrasive 70′ and the abrasive grains72 together with a common gas flow. By mixing the recovered abrasive 70′and the abrasive grains 72 together in the solid-gas two-phase flow, newabrasive grains 72 are adhered to the surface of the cores 71 of therecovered abrasive 70′ where the surface had been exposed by theabrasive grains being fallen off by the adhesive force processed by thecores 71. By the mixing performed in the gas flow as described above,the abrasive grains 72 are adhered to portions where the abrasive grains72 had been fallen off while preventing particles of the recoveredabrasive 70′ from combining and clumping together.

An example of the mixer 11 to mix the recovered abrasive 70′ and theabrasive grains 72 together in the gas flow in the manner describedabove is illustrated in FIG. 3.

The mixer 11 illustrated in FIG. 3 is a configuration including a firstbody 111 having with an abrasive grain intake chamber 112 formed insideand a second body 113 formed with a recovered abrasive intake chamber114 inside that are connected together through an intermediate housing115, a first air jet 116 in communication with a rear end of anon-illustrated compressed gas supply and having a leading end of thefirst air jet 116 inserted into the abrasive grain intake chamber 112 ofthe first body 111, with the leading end of the first air jet 116 alsofacing toward the rear end of a second air jet 117, wherein the leadingend of the second air jet 117 is inserted into the recovered abrasiveintake chamber 114 and faces toward an outlet 118 of the mixer 11.

An intake port 112 a of the abrasive grain intake chamber 112 is incommunication with the abrasive grain feeder 13 through an abrasivegrain feed pipe 42 (see FIG. 2), and an intake port 114 a of therecovered abrasive intake chamber 114 is in communication with thebottom section of the abrasive recovery section 20 through a recoveredabrasive feed pipe 43 (see FIG. 2).

Note that in the illustrated example, each of the components of theconfiguration of the mixer as described above are formed separately, andthe mixer 11 is formed by their combination. However, instead of such aconfiguration, for example, the mixer 11 may be integrally manufactured,i.e. not from separate components, by using a metal 3D printer that usesa laser fusion method, an electron beam fusion method, or the like.

Manufacture using a 3D printer in this manner is beneficial from theperspective of manufacturing speed and cost compared to manufacturing bya machine processing cutting method or the like, and is also beneficialfrom the cost perspective when producing in large volumes.

Examples of the metal employed to manufacture such a mixer 11 include amaraging steel, a titanium alloy, a stainless steel alloy, acobalt-chromium alloy, a nickel alloy, an Inconel (registeredtrademark), or another metal or alloy.

In the mixer 11 equipped with the above configuration, when a compressedgas is fed from the compressed gas supply to the first air jet 116 andejected from the leading end of the first air jet 116 toward the rearend of the second air jet 117, a negative pressure develops inside theabrasive grain intake chamber 112 due to compressed gas ejection,abrasive grains 72 from the abrasive grain feeder 13 are accordinglysucked into the abrasive grain intake chamber 112, and are merged withthe compressed gas being ejected from the leading end of the first airjet 116 before being fed into the second air jet 117.

The mixed flow of the abrasive grains 72 and the gas flow fed into thesecond air jet 117 is ejected into the recovered abrasive intake chamber114 in the direction toward the outlet 118 of the mixer 11. A negativepressure accordingly develops inside the recovered abrasive intakechamber 114, and some of the recovered elastic abrasive inside theabrasive recovery section 20 is accordingly fed into the recoveredabrasive intake chamber 114 as recovered abrasive 70′ to be regenerated.This merges with the gas flow containing abrasive grains, and results ina solid-gas two-phase flow being ejected from the mixer 11.

In this manner, the abrasive grains 72 and the recovered abrasive 70′are caused to merge together with the gas flow to generate the solid-gastwo-phase flow, the abrasive grains 72 and the recovered abrasive 70′ inthe solid-gas two-phase flow are mixed together without clumping or thelike, and new abrasive grains 72 are adhered to the surface of the cores71 of the recovered abrasive 70′ where the surface had been exposed bythe abrasive grains 72 being fallen off.

The quantity of elastic abrasive fed as the recovered abrasive 70′ fromthe abrasive recovery section 20 into the mixer 11 in a specific periodof time (g/minute) is preferably adjusted to be from 5% to 50% of thequantity of the elastic abrasive being ejected into the blasting chamberin a specific period of time (g/minute), and is more preferably adjustedso as to be from 10% to 30% thereof.

Moreover, the feed rate of abrasive grains fed into the mixer 11 ispreferably not more than 3.0% of the feed rate of recovered abrasive,and is more preferably not more than 1.0% thereof.

In cases in which more than 3.0% of the abrasive grains 72 is fed thenthis results in more abrasive grains 72 being fed in than a quantitythat would cover the entire surface of the recovered abrasive 70′, andin the generation of lots of free abrasive grains that are not able tobe adhered to the surface of the recovered abrasive 70′. Such freeabrasive grains are returned in the abrasive re-circulation systemtogether with the regenerated elastic abrasive 70 and ejected againstthe workpiece. As well as this causing the treatment state todeteriorate, such as by forming a matt finish or the like on the surfaceof a workpiece, these free abrasive grains are also subsequentlyrecovered inside the dust collector 26 by air sorting in the abrasiverecovery section 20 and discarded, resulting in the cost of the blastingincreasing and having a significant negative economic impact,particularly when expensive abrasive grains such as diamond, siliconcarbide, cBN or the like are employed.

Note that although in the illustrated example the space inside the firstbody 111 is configured by the abrasive grain intake chamber 112, and thespace inside the second body 113 is configured by the recovered abrasiveintake chamber 114, a reverse configuration may be adopted in which thespace inside the first body 111 is formed as a recovered abrasive intakechamber in communication with the abrasive recovery section 20, and thespace inside the second body 113 is formed as an abrasive grain intakechamber 112 in communication with the abrasive grain feeder 13. There isno limitation to the illustrated configuration, as long as the gas flowcontaining the abrasive grains 72 and the gas flow containing therecovered abrasive 70′ are merged and mixed together, and as long as theabrasive grains can be adhered to the surface of the recovered abrasive70′. Various modifications are accordingly possible thereto.

Moreover, although in the illustrated example, a configuration has beendescribed in which mixing of the abrasive grains 72 with the recoveredabrasive 70′ is performed in the gas flow, as long as both can be mixedtogether and the abrasive grains can be caused to adhere to the surfaceof the cores 71 of the recovered abrasive 70′, the configuration of themixer 11 is not limited to the illustrated configuration.

Combining Unit

For the recovered abrasive 70′ that has passed through the mixer 11 asdescribed above, new abrasive grains 72 are adhered to the surface ofthe cores 71 by the mixing in the mixer 11. However, the adhering ofsuch abrasive grains 72 is merely adhering to the surface by theadhesive force processed by the cores 71 of the abrasive grains 72, andthe state of combination between the cores 71 and the abrasive grains 72may still be a weak state.

This means that the recovered abrasive 70′ is not able to be re-employedas the elastic abrasive 70 when still in such a state. In order toachieve a state capable of withstanding reuse, the abrasive grains 72need to be pressed against the surface of the cores 71 of the recoveredabrasive 70′, and to be caused to combine strongly therewith by part ofthe abrasive grains 72 being embedded into the cores 71.

In order to enable the cores 71 and the abrasive grains 72 to combinestrongly together in this manner, the recovered abrasive 70′ after beingmixed by the mixer 11 is fed into the combining unit 12 equipped with aconstricted flow path 121 that gradually narrows in flow pathcross-sectional area, and the abrasive grains 72 are pressed against thesurface of the cores 71 by aggregate bodies of the recovered abrasive70′ being compressed while they are being passed through the constrictedflow path 121 in an aggregated state.

Examples of configurations of the combining unit 12 equipped with such aconstricted flow path 121 are illustrated in FIG. 4 to FIG. 6.

In FIG. 4 thereof, the constricted flow path 121 is formed between twoflat plates 122, 122, and pressing faces 124, 124 are formed by thesurface of walls defining the constricted flow path 121 configured bythe respective surfaces of the flat plates 122, 122. The two flat plates122, 122 are arranged with a specific angle formed therebetween suchthat the separation between the pressing faces 124, 124 is a separationthat gradually narrows on progression from a wide separation section 125to a narrow separation section 126. The constricted flow path 121 isaccordingly formed with a width that narrows toward the bottom of thepage.

The flow path cross-sectional area and the like of this constricted flowpath 121 is adjusted so that the recovered abrasive 70′, which is beingfed from the mixer 11 as the solid-gas two-phase flow through a pipeline16 a as illustrated in FIG. 5, passes through the constricted flow path121 in an aggregate state in which particles of recovered abrasive 70′are contacting each other. Aggregate bodies of recovered abrasive 70′are thereby compressed as they move in the constricted flow path 121from the wide separation section 125 to the narrow separation section126, and the density thereof rises. The particles of the recoveredabrasive 70′ therefore pass through the narrow separation section 126 ina state compressed against each other, and the abrasive grains 72 thatare adhered to the surface of the cores 71 are pressed toward the centerof the cores 71, resulting in at least part of the abrasive grains 72becoming embedded in the cores 71 so as to achieve strong combinationtherewith.

In this manner, in the example in which the constricted flow path 121 isformed between the two flat plates 122, 122, the compressed state of therecovered abrasive 70′ passing through the constricted flow path 121,and hence the pressing force of the abrasive grains 72 against thesurface of the cores 71, can be changed by changing the angle formed bythe two flat plates 122, 122 and/or by modifying the flow pathcross-sectional area d of the narrow separation section 126. Theabrasive grains 72 can accordingly be pressed against the surface of thecores 71 by the most appropriate pressing force by adjusting the abovecompressed state of the recovered abrasive 70′ and the pressing force ofthe abrasive grains 72 against the surface of the cores 71 according tothe physical properties of the cores 71 and the abrasive grains 72 ofthe recovered abrasive 70′, the environmental conditions, and the like.

Note that in the thus configured combining unit 12, a straight flow path129 connected to the constricted flow path 121, and having a flow pathcross-sectional area d of the narrow separation section 126 and aspecific length, may be provided as illustrated in FIG. 5, such that theaggregate bodies of the recovered abrasive 70′ are retained in aspecific compressed state for a specific period of time before they passout of the straight flow path 129.

Moreover, in cases in which the constricted flow path 121 is formed inthis manner by flat plates 122, 122, a vibration may be imparted to theflat plates 122, 122. This causes the particles of the recoveredabrasive 70′ to make even closer contact with each other, raising thepressing force of the abrasive grains against the surface of the cores71, and also enabling the recovered abrasive 70′ to be prevented fromclogging inside the constricted flow path 121.

The combining unit 12 described with reference to FIG. 4 is an exampleof a configuration in which the pressing faces 124, 124 respectivelyformed by the walls defining the constricted flow path 121 are formed bythe surfaces of the flat plates 122, 122, however, one or both of thepressing faces 124, 124 defining the constricted flow path 121 may beformed by an outer peripheral face of a cylindrical roller 123.

FIG. 6A illustrates an example of a constricted flow path 121, depictedin the drawing with grey infill, configured by a surface of a flat plate122 as one of the pressing faces 124, 124 defining the constricted flowpath 121, and by the outer peripheral face of a roller 123 (the outerperipheral portion thereof depicted in the drawing with diagonalshading) as the other thereof. FIG. 6B illustrates an example of aconstricted flow path 121, depicted in the drawing with grey infill, inwhich both of the pressing faces 124, 124 defining the constricted flowpath 121 are formed by respective outer peripheral faces (outerperipheral portions thereof depicted with diagonal shading in thedrawing) of rollers 123, 123 arranged at a specific separation from eachother. Moreover, FIG. 6C illustrates an example in which two pairs ofrollers 123, 123; 123, 123 are arranged above and below each other, suchthat after passing through the constricted flow path 121 formed betweenthe upper rollers 123, 123, the recovered abrasive 70′ can then be fedinto a constricted flow path 121′ formed between the additional lowerrollers 123, 123.

By adopting such a configuration in which at least one of the pressingfaces 124, 124 defining the constricted flow path 121 is formed by theouter peripheral face of a roller 123, combining is performed byrotating the roller 123 in the direction of the arrow in the drawing soas to move the pressing face 124 formed by the outer peripheral face ofthe roller 123 along the constricted flow path 121 in the direction fromthe wide separation section 125 side toward the narrow separationsection 126 side.

As a result, the recovered abrasive 70′ fed into the constricted flowpath 121 in an aggregated state is compressed by being forcibly movedalong the constricted flow path 121 toward the narrow separation section126 side by such rotation of the roller 123. This enables the abrasivegrains 72 to be pressed with a strong force against the surface of thecores 71 of the recovered abrasive 70′, enabling a higher combiningstrength of the abrasive grains 72 with the surface of the cores 71 tobe achieved.

Note that the combining units 12 illustrated in FIG. 6A and FIG. 6B eachadopt a configuration in which the recovered abrasive 70′ from the mixer11 is first fed into a hopper 127, and then the recovered abrasive 70′that falls out from the hopper is fed into the constricted flow path 121provided below. However, as illustrated in FIG. 6C, a configuration maybe adopted in which such a hopper 127 is omitted, and the recoveredabrasive 70′ that has passed through the mixer 11 is fed directly intothe constricted flow path 121 formed between the rollers 123, 123.

Moreover, by providing the functionality of the constricted flow path121, as described with reference to FIG. 4A or FIG. 4B, to a flow pathformed inside the hopper 127 provided to the combining unit 12 of FIG.6A or FIG. 6B, the recovered abrasive 70′ that has passed through themixer 11 may then be primary compressed in the hopper 127, then therecovered abrasive 70′ is further compressed in the constricted flowpath 121 provided below.

Note that in cases in which compression of the recovered abrasive 70′ isperformed plural times in this manner, a configuration provided with twostage upper and lower roller pairs 123, 123 as illustrated in FIG. 6Cmay be adopted, and the recovered abrasive 70′ that has passed throughthe constricted flow path 121 formed between the upper roller pair 123,123 is then fed into the constricted flow path 121′ formed between thelower roller pair 123, 123, so as to enable the abrasive grains to bepressed against the surface of the cores 71 of the recovered abrasive70′ two times.

Furthermore, compressing of the recovered abrasive 70′ is not limited tothe examples illustrated, and compressing may be performed three or moretimes by providing three or more stages of constricted flow paths 121.

In such a multi-stage configuration of constricted flow paths 121, aconfiguration may be adopted in which a flow path cross-sectional aread2 of a narrow separation section 126 of a lower (downstream)constricted flow path 121′ is formed smaller than a flow pathcross-sectional area d1 of a narrow separation section 126 of an upper(upstream) constricted flow path 121, so as to achieve a configurationin which the compression ratio of the aggregate bodies of the recoveredabrasive 70′, and therefore the pressing force of the abrasive grains 72against the surface of the cores 71 of the recovered abrasive 70′, isprogressively raised in stages.

Note that in cases in which one or more of the pressing faces 124 of theconstricted flow path 121 is formed by the outer peripheral face of aroller 123, as illustrated in FIG. 6A to FIG. 6C, although a width ofthe constricted flow path at the narrow separation section 126 differsdepending on the physical properties of the abrasive grains 72 and thecores 71, the particle diameter and amount of the recovered abrasive 70′to be regenerated, and the like, this width is adjusted so as to achieveoptimal pressing force according to the physical properties of the core(for example, the strength of adhesiveness, hardness, or the like), thephysical properties of the abrasive grains (shape and particle diameteretc.), and the like, and is for example, from about 0.1 mm to about 10mm, and is more preferably in a range of from 0.2 mm to 5 mm.

Moreover, the materials employed for the flat plates 122 and the rollers123 configuring the constricted flow path 121 are not particularlylimited, and as long as they enable the cores 71 with abrasive grains 72adhered to the surface thereof by the mixer 11 to pass through, variousmaterials may be employed therefor without particular limitation.Examples thereof include resins, various single metals, alloys,structural carbon steels, tool steels, high speed steels, cementedcarbides, glass, ceramics, and the like.

Note that in the examples described above in which at least one of thepressing faces 124, 124 defining the constricted flow path 121 is formedby an outer peripheral face of the rollers 123, the abrasive grains 72on the surface of the cores 71 may pass through without beingsufficiently pressed if the rotation speed of the roller 123 is toofast, resulting in a weak combining strength of the abrasive grains 72to the cores 71, and in the abrasive grains 72 in the elastic abrasive70 regenerated in this manner being easily fallen off from the surfacein use.

However, if the rotation speed of the rollers 123 is too slow, then thisdecreases the amount of elastic abrasive 70 regenerated and soregeneration may not keep up. Moreover, the surface of the cores 71having adhesive properties may be externally exposed between theabrasive grains 72 adhered to the surface when passing between therollers 123, 123, leading to the cores 71 adhering and clumpingtogether, and resulting in the elastic abrasive 70 no longer beingreusable.

The rotation speed at the surface of the rollers 123 is accordinglypreferably from 1 m/min to 50 m/min, and more preferably from 5 m/min to30 m/min.

Abrasive Grain Feeder

Any structure may be employed for the configuration of the abrasivegrain feeder 13 for feeding the abrasive grains into the mixer 11, aslong as a configuration capable of quantitative feeding of abrasivegrains at a pre-set feed rate into the mixer 11 is adopted. For examplean abrasive grain feeder 13 having a comparatively simple structure maybe employed in which a hole or slit of a specific dimension is providedin a bottom section of a hopper for storing the abrasive grains, andthen the abrasive grains are fed into the mixer 11 by passing throughthe hole or slit.

In order to achieve smooth feeding of the abrasive grains, preferablyvibration is imparted to the hopper storing the abrasive grains. Inparticular, the cohesive force is strong in cases in which fine abrasivegrains having an abrasive grain size finer than 3000 grit (D50: 11 μm)are employed, and so the application of ultrasound vibration is requiredin such cases since such fine abrasive grains are not able to beconveyed otherwise.

In the present exemplary embodiment, the abrasive grain metering means131 illustrated in FIG. 7 and FIG. 8 is provided in the abrasive grainfeeder 13 so as to enable accurate metering and feeding of such fineabrasive grains, and in particular of abrasive grains of 6000 grit (D50:2 μm) or finer which have a strong cohesive force.

The abrasive grain feeder 13 equipped with such an abrasive grainmetering means 131 is configured including a screen 133 disposed below ahopper 132 formed in a funnel shape. The screen 133 is configured fromperforated metal or mesh formed with multiple small holes of from 0.1 mmto 2 mm in a configuration in which abrasive grains poured into thehopper 132 are allowed to fall onto the screen 133. A stirring blade 135that rotates inside the hopper 132, and a scraper 136 that rotates overthe screen 133, are attached to a rotation shaft 134 a provided to astirring motor 134 disposed above the hopper 132, in a configurationenabling the stirring blade 135 and the scraper 136 to be rotatedaccompanying rotation of the stirring motor 134.

A blade 137 that makes sliding contact with the surface of the screen133 as the scraper 136 rotates is provided to the scraper 136 in aconfiguration such that the abrasive grains can be caused by the blade137 to fall through the small holes formed in the screen 133.

Thus by rotating the stirring motor 134 in a state in which the abrasivegrains have been poured into the hopper 132, the abrasive grains in thehopper 132 are stirred by the stirring blade 135 and fall onto thescreen 133.

These abrasive grains are fed into the small holes in the screen 133 bythe blade 137 due to the rotation of the scraper 136, and the abrasivegrains pass through the small holes in the screen 133 and fall downwardsat small quantities each time.

Thus in the abrasive grain feeder 13 equipped with the abrasive grainmetering means 131 configured as described above, the abrasive grainfeed rate can be increased by speeding up the rotation speed of thestirring motor 134, and conversely the abrasive grain feed rate can bedecreased by lowering the rotation speed of the stirring motor 134. Aconfiguration is accordingly achieved such that the abrasive grain feedrate can be varied by controlling the rotation speed of the stirringmotor 134.

An abrasive grain receiver 130 into which abrasive grains that havepassed through the screen 133 fall is communicated through the abrasivegrain feed pipe 42 with the abrasive grain intake chamber 112 providedin the mixer 11. When a compressed gas is fed into the mixer 11 throughthe first air jet 116 and a negative pressure is induced in the abrasivegrain intake chamber 112, abrasive grains are fed into the mixer 11together with the external air that has been sucked in through anexternal air intake port 130 a provided to the abrasive grain receiver130.

Detection Means and Control Means (Feedback Control)

In the blasting device 1 of the present invention in which the abrasivegrain metering means 131 is provided to the abrasive grain feeder 13 tovary the abrasive grain feed rate, a configuration may be adopted inwhich a detection means 14 is provided to measure the adhered amount ofabrasive grains to the cores of the regenerated elastic abrasiveobtained by the combining unit 12, so as to control the rate at whichthe abrasive grains are fed into the mixer 11 by feedback according todetection results from the detection means 14.

The measurement of the adhered amount of abrasive grains may, forexample, be derived based on images from imaging the surface ofparticles of regenerated elastic abrasive extracted as a sample of theregenerated elastic abrasive obtained, and derived as a ratio of thenumber of pixels of portions where abrasive grains are adhered withrespect to the number of pixels of portions where no abrasive grains areadhered. However, in the present exemplary embodiment the adhered amountof abrasive grains is measured by the angle of repose of the regeneratedelastic abrasive, which is the pile angle formed when regeneratedelastic abrasive is piled up in a cone shape.

Namely, as the adhered amount of abrasive grains changes, the larger theexposed surface area of the core surface that has adhesive properties,the more easily the particles of the obtained regenerated elasticabrasive adhere to each other and cohere together, and the smaller theexposed surface area of the core surface, the less likely particles ofthe regenerated elastic abrasive are to cohere together. As a result,the angle of repose is greater in cases in which there is insufficientadhering of the abrasive grains to the core and the core is exposed.This means that the adhered state of abrasive grains to the core surfacecan be measured by measuring the angle of repose of the regeneratedelastic abrasive.

Various sensors or a CCD camera or the like may be employed as examplesof the detection means 14 for measuring such an angle of repose. Forexample, the regenerated elastic abrasive may be piled up on a circulardisc provided at a position not liable to be affected by thesurroundings until the regenerated elastic abrasive starts to fall off,and the angle of repose measured based on a video imaging the angle ofrepose of the piled up regenerated elastic abrasive or based on theheight of the pile.

A detection chamber 50 in communication with the blasting chamber 8 isprovided in the illustrated exemplary embodiment. The regeneratedelastic abrasive is allowed to fall onto a detection plate 51 providedinside the detection chamber 50 and to pile up thereon, and theregenerated elastic abrasive that has fallen from the detection plate 51is allowed to fall into the blasting chamber 8, so as to enable theregenerated elastic abrasive to be returned to the abrasivere-circulation system. This enables a detection process by the detectionmeans 14 to be performed in a continuous sequence of actions.

The angle of repose of the regenerated elastic abrasive measured by thedetection means 14 in this manner is sent to the control means 15.

The control means 15 is, for example, a microcontroller for controllingthe rotation speed of the stirring motor 134 provided to the abrasivegrain feeder 13 based on the angle of repose received from the detectionmeans 14. Based on pre-stored correspondence relationships between theangle of repose and the rotation speed of the stirring motor 134, themicrocontroller then speeds up the rotation speed of the stirring motor134 and increases the abrasive grain feed rate in cases in whichmeasured angle of repose is greater than a target angle of repose, so asto make the measured angle of repose approach the target angle of reposeand obtain regenerated elastic abrasive of a constant quality.

Modified Examples Etc.

In the blasting device 1 of the present invention as described above, aconfiguration has been described in which the elastic abrasiveregeneration device 10 is provided outside the abrasive re-circulationsystem of the blasting device 1, and some of the elastic abrasiverecovered in the abrasive recovery section 20 is regenerated. However,for example, the mixer 11 and the combining unit 12 may be provided on aflow path from the abrasive recovery section 20 to the abrasive ejectionmeans 30, and all of the elastic abrasive recovered in the abrasivere-circulation system subjected to the regeneration process.

Moreover, although an example has been described above of a case inwhich the elastic abrasive regeneration device 10 is provided as oneconfiguration element of the blasting device 1, the elastic abrasiveregeneration device 10 described above may be detached from the blastingdevice 1, and employed as a standalone elastic abrasive manufacturingdevice.

In such cases, the recovered abrasive 70′ described as being the targetfor regeneration in the elastic abrasive regeneration device 10 of theabove exemplary embodiment may be replaced with unused cores 71 or bycores 71 that have already been used.

EXAMPLE

Description follows regarding the results of tests performed to checkthe performance of the blasting device of the present invention equippedwith the elastic abrasive regeneration device.

Test Aims

The aim of the tests was to confirm that there was no reduction incutting performance when performing blasting using the blasting deviceof the present invention equipped with the elastic abrasive regenerationdevice, and to confirm that stable cutting performance could be obtainedfor a prolonged period of time therewith.

Test Method

The elastic abrasive employed was configured by cores made of anelastomer with self-adhesive properties (having an average major axisdimension of from 0.3 mm to 1.0 mm), with 10000 grit (D50: 0.6 μm)diamond abrasive grains adhered to the surface thereof at an amount of30% by weight relative to the cores (“Series Z” manufactured by FujiManufacturing Co., Ltd).

The blasting device employed in the Example was based on a commerciallyavailable pneumatic blasting device (“SFZ-2” manufactured by FujiManufacturing Co., Ltd), and provided with the elastic abrasiveregeneration device described with reference to FIG. 1 and FIG. 2. Onthe other hand, the blasting device employed in the Comparative Examplewas based on the pneumatic blasting device (“SFZ-2” manufactured by FujiManufacturing Co., Ltd), and provided with a configuration in which themixer 11 of the elastic abrasive regeneration device described withreference to FIG. 1 and FIG. 2 alone (i.e. a configuration in which therecovered abrasive 70′ that has passed through the mixer 11 is thenreturned to the abrasive recovery section 20 without passing through thecombining unit 12). Feedback control was not performed in either theExample of the Comparative Example. Blasting was performed continuouslytherewith under the conditions listed in Table 1 on a test piece (a 90mm square of 2 mm thick SUS 304 sheet), and changes to the treatmentstate with the passage of treatment time were observed.

TABLE 1 Blasting Conditions (Common to Example and Comparative Example)Blasting device SFZ-2 (Manufactured by Fuji Manufacturing Co., Ltd)Elastic abrasive SID#10000 (manufactured by Fuji Manufacturing Co., Ltd)Abrasive grains employed Diamond (10000 grit) for regeneration (grainsize) Quantity of elastic abrasive 1000 g Blast gun F2-1 model, 9 mmdiameter (manufactured by Fuji Manufacturing Co., Ltd) Treatmentpressure 0.3 MPa Ejection Treatment 2000 g/min rate path Regeneration200 g/min path Ejection direction and 20 mm in a vertical directionejection distance (between gun and workpiece) Ejection angle (gun 20°inclination angle) Treatment workpiece SUS 304 sheet (90 mm × 90 mm × 2mm) (test piece) Regeneration abrasive grains 0.045 g/min feed rate

Note that the combining unit provided in the abrasive regenerationdevice of the blasting device of the Example is a roller type ofcombining unit with the configuration stated in Table 2 below.

TABLE 2 Configuration of Combining unit Provided to Blasting Device ofExample Type Roller type Roller shape Cylindrical, 50 mm diameter, 80 mmlength Roller material S45C Roller surface roughness Ra 0.088 μm Numberof rollers One pair (one stage) Roller separation 1.0 mm (width atnarrow separation section) Roller rotation speed 116 min⁻¹ (about 18m/min)

Test Results

FIG. 9 illustrates changes to a relationship between ejection time andtreatment rate (cutting rate) as blasting is performed using theblasting device of the present invention equipped with the elasticabrasive regeneration device.

As is apparent from FIG. 9, the blasting performed using the blastingdevice of the present invention was confirmed to enable blasting to beperformed at a stable treatment rate for a prolonged period of time (a120 hour duration) from the start of treatment to completion of the test(FIG. 9).

The above results enabled confirmation that in the blasting device ofthe present invention, elastic abrasive is regenerated in a suitablemanner by the elastic abrasive regeneration device.

However, in the blasting device of the Comparative Example, fragments ofcores of the elastic abrasive from which abrasive grains have beenfallen off start to adhere to the workpiece after the elapse of 0.5hours from the start of blasting, and the adhered amount of cores to theworkpiece increased for 3 hours of treatment, at which point normaltreatment was no longer possible.

In the blasting device of the Comparative Example, mixing of therecovered abrasive and the abrasive grains was also performed by themixer, and new abrasive grains were adhered to the core surface of therecovered abrasive where the surface had been exposed by abrasive grainsbeing fallen off.

However, the blasting device of the Comparative Example was not equippedwith a combining unit, and so the abrasive grains adhered by the mixerdid not combine with the surface of the cores, and it is thought that asa result of this the abrasive grains adhered in the mixer were readilyfallen off, so that the core was exposed and adhered to the workpiece.

The configuration in which a combining unit is provided in the elasticabrasive regeneration device and the abrasive grains are pressed againstthe surface of the cores was accordingly confirmed to be extremelyeffective in combining the abrasive grains strongly to the surface ofthe core.

Thus the broadest claims that follow are not directed to a machine thatis configured in a specific way. Instead, said broadest claims areintended to protect the heart or essence of this breakthrough invention.This invention is clearly new and useful. Moreover, it was not obviousto those of ordinary skill in the art at the time it was made, in viewof the prior art when considered as a whole.

Moreover, in view of the revolutionary nature of this invention, it isclearly a pioneering invention. As such, the claims that follow areentitled to very broad interpretation so as to protect the heart of thisinvention, as a matter of law.

It will thus be seen that the objects set forth above, and those madeapparent from the foregoing description, are efficiently attained andsince certain changes may be made in the above construction withoutdeparting from the scope of the invention, it is intended that allmatters contained in the foregoing description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

It is also to be understood that the following claims are intended tocover all of the generic and specific features of the invention hereindescribed, and all statements of the scope of the invention which, as amatter of language, might be said to fall therebetween.

Now that the invention has been described;

DESCRIPTION OF REFERENCE NUMERALS

-   1 Blasting device-   7 Cabinet-   8 Blasting chamber-   10 Elastic abrasive regeneration device-   11 Mixer    -   111 First body    -   112 Abrasive grain intake chamber    -   112 a Intake port    -   113 Second body    -   114 Recovered abrasive intake chamber    -   114 a Intake port    -   115 Intermediate housing    -   116 First air jet    -   117 Second air jet    -   118 Outlet-   12 Combining unit    -   121, 121′ Constricted flow path    -   122 Flat plate    -   123 Roller    -   124 Pressing face    -   125 Wide separation section    -   126 Narrow separation section    -   127 Hopper    -   129 Straight flow path-   13 Abrasive grain feeder    -   130 Abrasive grain receiver    -   130 a External air intake port    -   131 Abrasive grain metering means    -   132 Hopper    -   133 Screen    -   134 Stirring motor    -   134 a Rotation shaft    -   135 Stirring blade    -   136 Scraper    -   137 Blade-   14 Detection means-   15 Control means-   16 a,16 b Pipeline-   20 Abrasive recovery section-   25 Extractor fan (blower)-   26 Dust collector-   30 Abrasive ejection means (blast gun)-   41 Abrasive feed pipe-   42 Abrasive grain feed pipe-   43 Recovered abrasive feed pipe-   50 Detection chamber-   51 Detection plate-   70 Elastic abrasive-   70′ Used recovered abrasive-   71 Core-   72 Abrasive grain

1. A method of manufacturing an elastic abrasive having a structure inwhich abrasive grains have been combined to a surface of cores that areformed from an elastic material and at least the surface has adhesiveproperties, the elastic abrasive manufacturing method comprising: amixing process in which the cores and the abrasive grains are mixedtogether and the abrasive grains are adhered to the surface of thecores; and a combining process in which the abrasive grains are pressedagainst and combined to the surface of the cores by passing the coresthat have completed the mixing process through a constricted flow pathhaving a gradually narrowing flow path cross-sectional area with thecores in an aggregated state so as to compress aggregate bodies of thecores.
 2. The elastic abrasive manufacturing method of claim 1, whereinthe combining process is executed by forming the constricted flow pathbetween two pressing faces arranged such that a spacing therebetweengradually narrows on progression from a wide separation section to anarrow separation section, and passing the cores that have completed themixing process along the constricted flow path from the wide separationsection toward the narrow separation section.
 3. The elastic abrasivemanufacturing method of claim 2, wherein at least one of the pressingfaces is formed by an outer peripheral face of a cylindrical roller, andthe combining process is executed by rotating the roller so that thepressing face formed by the outer peripheral face of the roller movesalong the constricted flow path from the wide separation section towardthe narrow separation section.
 4. The elastic abrasive manufacturingmethod of claim 1, wherein a plurality of the constricted flow paths arearranged in series, and after passing the cores that have completed themixing process through one constricted flow path provided upstream, thecores are also passed through another constricted flow path provideddownstream of the one constricted flow path, so that pressing of theabrasive grains against the surface of the cores in the combiningprocess is performed a plurality of times corresponding to the number ofthe constricted flow paths formed.
 5. The elastic abrasive manufacturingmethod of claim 4, wherein a flow path cross-sectional area of a narrowseparation section of the other constricted flow path is narrower than aflow path cross-sectional area of a narrow separation section of the oneconstricted flow path, and a pressing force of the abrasive grainsagainst the surface of the cores in the combining process isprogressively raised in stages.
 6. A device for manufacturing an elasticabrasive having a structure in which abrasive grains have been combinedto a surface of cores that are formed from an elastic material and atleast the surface has adhesive properties, the elastic abrasivemanufacturing device comprising: a mixer configured to mix the cores andthe abrasive grains together and to adhere the abrasive grains to thesurface of the cores; and a combining unit including a constricted flowpath having a gradually narrowing flow path cross-sectional area, withthe cores that have been mixed in the mixer being passed through thecombining unit in an aggregated state.
 7. The elastic abrasivemanufacturing device of claim 6, wherein the constricted flow path isformed between two pressing faces arranged such that a spacingtherebetween gradually narrows on progression from a wide separationsection to a narrow separation section.
 8. The elastic abrasivemanufacturing device of claim 7, wherein at least one of the pressingfaces is formed by an outer peripheral face of a cylindrical roller, andthe roller is configured so as to be rotatable such that the pressingface formed by the outer peripheral face of the roller moves along theconstricted flow path from the wide separation section toward the narrowseparation section.
 9. The elastic abrasive manufacturing device ofclaim 6, wherein a plurality of the constricted flow paths are arrangedin series.
 10. The elastic abrasive manufacturing device of claim 9,wherein in comparison to a flow path cross-sectional area of a narrowseparation section of one constricted flow path arranged upstream in theplurality of constricted flow paths, a flow path cross-sectional area ofa narrow separation section of another constricted flow path arrangeddownstream of the one constricted flow path is narrower.
 11. A blastingmethod employing a re-circulatory type blasting device including ablasting chamber where ejection of an abrasive is performed, an abrasiverecovery section in communication with a bottom section of the blastingchamber, and an abrasive ejection means for ejecting abrasive frominside the abrasive recovery section into the blasting chamber, with anabrasive re-circulation system being formed to re-circulate the abrasivefrom the blasting chamber, through the abrasive recovery section, to theabrasive ejection means, and an elastic abrasive employed as theabrasive having a structure in which abrasive grains have been adheredto a surface of cores that are formed from an elastic material and haveadhesive properties at least at the core surface, the blasting methodcomprising: an elastic abrasive regeneration process in which at leastsome of recovered abrasive recovered in the abrasive recovery section isregenerated and returned into the abrasive re-circulation system,wherein the regeneration process includes a mixing process in which therecovered abrasive and abrasive grains are mixed together and theabrasive grains are adhered to the surface of the cores of the recoveredabrasive; and a combining process in which the abrasive grains arepressed against and combined to the surface of the cores of therecovered abrasive by passing the recovered abrasive that has completedthe mixing process in an aggregated state along a constricted flow pathhaving a gradually narrowing flow path cross-sectional area and bycompressing aggregate bodies of the recovered abrasive.
 12. The blastingmethod of claim 11, wherein the combining process is executed by formingthe constricted flow path between two pressing faces arranged such thata spacing therebetween gradually narrows on progression from a wideseparation section to a narrow separation section, and passing therecovered abrasive that has completed the mixing process along theconstricted flow path from the wide separation section toward the narrowseparation section.
 13. The blasting method of claim 12, wherein atleast one of the pressing faces is formed by an outer peripheral face ofa cylindrical roller, and the combining process is executed by rotatingthe roller so that the pressing face formed by the outer peripheral faceof the roller moves along the constricted flow path from the wideseparation section toward the narrow separation section.
 14. Theblasting method of 11, wherein a plurality of the constricted flow pathsare arranged in series, and after the recovered abrasive that hascompleted the mixing process has been passed along one constricted flowpath provided upstream, the recovered abrasive is also passed alonganother constricted flow path provided downstream of the one constrictedflow path, so that pressing of the abrasive grains against the surfaceof the cores in the combining process is performed a plurality of timescorresponding to the number of the constricted flow paths formed. 15.The blasting method of claim 14 wherein a flow path cross-sectional areaof a narrow separation section of the other constricted flow path isnarrower than a flow path cross-sectional area of a narrow separationsection of the one constricted flow path, and a pressing force of theabrasive grains against the surface of the cores in the combiningprocess is progressively raised in stages.
 16. A blasting devicecomprising: a blasting chamber where ejection of an abrasive isperformed; an abrasive recovery section in communication with a bottomsection of the blasting chamber; and an abrasive ejection means forejecting abrasive from in the abrasive recovery section into theblasting chamber, with an abrasive re-circulation system being formed tore-circulate the abrasive from the blasting chamber, through theabrasive recovery section, to the abrasive ejection means, and anelastic abrasive employed as the abrasive having a structure in whichabrasive grains have been adhered to a surface of cores that are formedfrom an elastic material and have adhesive properties at least at thecore surface; and the blasting device including an elastic abrasiveregeneration device in which at least some of recovered abrasiverecovered in the abrasive recovery section is regenerated and returnedinto the abrasive re-circulation system, the regeneration deviceincluding a mixer configured to mix the recovered abrasive and theabrasive grains together and to adhere the abrasive grains to thesurface of the cores of the recovered abrasive; and a combining unitincluding a constricted flow path having a gradually narrowing flow pathcross-sectional area in which the recovered abrasive that has been mixedin the mixer is passed through the combining unit in an aggregatedstate.
 17. The blasting device of claim 16, wherein the constricted flowpath is formed between two pressing faces arranged such that a spacingtherebetween gradually narrows on progression from a wide separationsection to a narrow separation section.
 18. The blasting device of claim17, wherein at least one of the pressing faces is formed by an outerperipheral face of a cylindrical roller, and the roller is configured soas to be rotatable such that the pressing face formed by the outerperipheral face of the roller is moved along the constricted flow pathfrom the wide separation section toward the narrow separation section.19. The blasting device of claim 16, wherein a plurality of theconstricted flow paths are arranged in series.
 20. The blasting deviceof claim 19, wherein in comparison to a flow path cross-sectional areaof a narrow separation section of one constricted flow path arrangedupstream in the plurality of constricted flow paths, a flow pathcross-sectional area of a narrow separation section of anotherconstricted flow path arranged downstream of the one constricted flowpath is narrower.